200 & 300 SERIES Diesel Fuel/Water Separators

Transcription

1 200 & 300 SERIES Diesel Fuel/Water Separators Installation Operation Parts Service Information

2 INSTALLATION A. FILTER MOUNTED ABOVE FUEL STORAGE TANK 1. Select a location in the fuel line between the fuel tank and the fuel pump, ahead of the vacuum side filters. All secondary or pressure side filters located between the pump and the engine should be serviced and left in place. 2. Mount the DAHL unit vertically on the vacuum (suction) side of all fuel pumps in a convenient location for servicing and inspection of contaminants in the bowl. Locate the height of the unit between the bottom of the fuel tank and the inlet of the fuel pump if possible. See Figure 1. DAHL recommends a 286-SK Mounting Bracket Shock Pad Kit if the filter will be subject to excessive vibration. NOTE: Allow 2 1/2 inches vertical clearance below the unit for servicing the element and draining the contaminants. 3. Install the fuel line from the fuel tank to the DAHL filter INLET using appropriate non-ga l vanized fittings. See DAHL Fittings Chart on Page Install the fuel line from the DAHL filter OUTLET to the INLET of the transfer or fuel pump. N OT E : To obtain maximum element life, remove as much mechanical restriction as possible from the system by doing the follow i n g : a. Remove the primary filter (if this does not affect warranty). b. Use the largest diameter fuel line that is practical. c. Mount the unit as near to the level of the pump as possible. d. Eliminate sharp bends in the fuel lines wherever possible. The best indicator of a fuel element s condition is a vacuum ga u g e. (See 85-VK Series in Form 4005.) A tapped fitting is recommended for mounting the gauge on the OUTLET port of the DAHL filter unit. (Manifold units are already tapped and plugged.) Remove the 1/8 inch plug and install the vacuum gauge there. Fittings and gauges are available from your dealer, or contact Baldwin Filters. Prime the fi l t e r as indicated under ELEMENT REPLACEMENT section. B. FILTER MOUNTED BELOW FUEL STORAGE TANK Installation procedures are the same as above plus an addition to Step 3: A ball- or butterfly-type shut-off valve must be installed ahead of the DAHL unit INLET. See Figure 2. This valve is necessary to shut off the fuel when changing the element. Valves are available from your dealer. NOTE: Va l ve not required when installing DAHL va l ve d manifold units. 2 FIGURE 1 REBUILD PROCEDURE If it is ever necessary to dismantle the unit for inspection and/or possible repairs, refer to the parts illustration. Then follow these simple steps: 1. Refer to appropriate ELEMENT REPLACEMENT steps for disassembly. (Dismount if desired.) 2. R e m ove the socket head bolts from the bowl ring to release the b owl. Stubborn bolts are easily removed by shocking the head. Place the allen wrench into the bolt and lightly rap the wrench with a hammer. Remove the bolt. 3. U n s c r ew the depressurizer cone to inspect the reverse flow va l ve. C a u t i o n : Cone edges are sharp. Use gloves or a rag for protection. MODELS 200 & 300 SPECIFICATIONS AND APPLICATIONS MODEL 200 F l ow Rate: Recommended 120 GPH (U.S.) (454 LPH) Maximum 200 GPH (U.S.) (757 LPH) D i m e n s i o n s : Height 16 3/4 In. (425.5 mm) Depth 7 3/4 In. (196.9 mm) Element Removal Clearance: 2 1/2 In. (63.5 mm) Sump Water Capacity: 24 oz. (708 ml) Water Removal Effi c i e n c y : Virtually 100% Used on: 8 Cylinder Cummins and Detroit Diesel Engines Caterpillar Engines up to Approximately 1,000 HP (Including 399) Most Medium Size Diesel Engines up to Approximately 1,000 HP Trucks, Buses, Construction and Agricultural Equipment Smaller Commercial Boats Medium Size Generators FIGURE 2 4. Check all parts for damage. Replace all damaged parts or hard gaskets. (Order Gasket Kit 200-GK.) 5. Refer to the parts illustration for reassembly. Clean all gasket grooves and contact surfaces of foreign matter. Coat the lid cover and bowl gaskets with grease and all other gaskets and O-Rings with oil. Hand tighten the depressurizer cone and wrench tighten the socket head bolts. 6. Again, refer to ELEMENT REPLACEMENT section to finish reassembly. MODEL 300 F l ow Rate: Recommended 180 GPH (U.S.) (681 LPH) Maximum 325 GPH (U.S.) (1,230 LPH) Dimensions: Height 22 1/4 In. (565.2 mm) Depth 7 3/4 In. (196.9 mm) Element Removal Clearance: 2 1/2 In. (63.5 mm) Sump Water Capacity: 24 oz. (708 ml) Water Removal Effi c i e n c y : Virtually 100% Used on: 12 & 16 Cylinder Cummins and Detroit Diesel Engines EMD and Alco Engines up to 2,000 HP Locomotive s Large Stationary Engines, Boats and Generators A ny Application with #12 Fuel Line Caterpillar Engines (800 HP and up)

3 DAHL FITTINGS CHART 90 Elbow Straight T h r e a d with O-Ring/37 Male JIC Note: Mount Model Before Installing Fittings. O-Ring Seal Fittings Require Care in Installation. DO NOT OVERTIGHTEN. See Instructions Below. FITTING FOR DAHL UNIT THREAD 1 THREAD 2 ORDER NUMBER Series 7/8-14 UNF 3 / x8 OBS 200 Series 7/8-14 UNF 7 / x Series 1 1/16-12 UNF 7 / x10 OBS 300 Series 1 1/16-12 UNF 1 1/ x Elbow Straight T h r e a d with O-Ring/37 Male JIC Drilled & Ta p p e d for #4 Vacuum Gauge Hose 37 Male JIC Straight T h r e a d with O-Ring 37 Female JIC S w i v e l - P u s h - O n Hose Fitting Female Pipe Straight T h r e a d with O-Ring 90 Swivel Elbow Straight Thread with O-Ring/37 Female JIC 90 Swivel Elbow Straight Thread with O-Ring/37 Female JIC Drilled & Tapped for #4 Vacuum Gauge Hose Series 7/8-14 UNF 3 / x 8 D TA 200 Series 7/8-14 UNF 3 / x 8 D T B 200 Series 7/8-14 UNF 3 / x8DTC OBS 200 Series 7/8-14 UNF 3 / x 8 D T D 200 Series 7/8-14 UNF 7 / x 10 D T B 300 Series 1 1/16-12 UNF 7 / x10DTB OBS 300 Series 1 1/16-12 UNF 1 1/ x12DTB OBS 200 Series 7/8-14 UNF 3 / x Series 7/8-14 UNF 7 / x Series 1 1/16-12 UNF 7 / x Series 1 1/16-12 UNF 1 1/ x Series 3 / /2 Hose x8 OBS 200 & 300 Series 7 / /8 Hose x10 OBS 300 Series 1 1/ /4 Hose x Series 7/8-14 UNF 3/8-18 NPT x Series 7/8-14 UNF 1/2-14 NPT x8 OBS 200 Series 7/8-14 UNF 3/4-14 NPT x Series 1 1/16-12 UNF 1/2-14 NPT x Series 1 1/16-12 UNF 3/4-14 NPT x Series 1 1/16-12 UNF 3 / F 200 Series 7/8-14 UNF 1 / D D T 1 Install Out Port First 2 Screw in O-Ring fitting until washer contacts port Hand Tighten Only Do NOT Use Wrench 3 4 Hold fitting by hand in desired position and tighten compression nut with wrench. Adjust Compression Nut All the Way Back YES (Important: Do Not Tighten Further) NO Turn Fitting Counterclockwise to Desired Position CAUTION: Use Low Torque: No More Than 8 Foot Pounds NOTE: Use Same Procedure for In Port. DAHL FITTINGS CROSS-REFERENCE CHART DAHL NUMBER AEROQUIP PARKER IMPERIAL WEATHERHEAD x S x6 OBS S F S O - 6 x 6 C 5515 x x8 OBS S F S O - 8 x 10 C 5515 x 8 x x S F S O - 10 x 10 C 5515 x x10 OBS S x S F S O - 12 x x4 OBS S F S O - 4 x 6 C 5315 x 4 x x S F S O - 6 x 6 C 5315 x 6 x x S F S O - 8 x 10 C 5315 x 8 x x S F S O - 10 x 10 C 5315 x x S C 5315 x 10 x x S F S O - 12 x 12 C 5315 x x B x6 OBS B x8 OBS B x10 OBS B x B x S C 3269 x 6 x x x C 3269 x 10 x x8 OBS S C 3269 x 10 x x C 3269 x 10 x x S C 3269 x 12 x x S C 3269 x 12 x 12 3

4 4 SERVICING DRAINING WATER NOTE: The bowl should always be drained before water or contaminant levels reach the bottom of the depressurizer cone. Check daily with the engine off. Always open the draincock completely to flush particulates out. Failure to do so could cause a leaky valve. A. DAHL Units Mounted HIGHER Than Fuel Storage Tank 1. Turn engine off. Vent the DAHL filter to allow draining. 2. Open the primer plug and then open the draincock and drain all contaminants. A. When To Replace As a general guideline, depending on fuel quality and engine use, elements should be replaced as follows: 1. DAHL 201 and 301 are 2 micron elements which can be used approximately 1000 hours or 40,000 miles. (DAHL 201-W and 301-W are 10 micron elements for use in winter or severe applications and DAHL and are 30 micron elements.) 2. If you have a vacuum gauge, the first replacement should be made at the very first indication of power loss at high RPMs. Make a note of the vacuum gauge reading at this point. The differences in various fuel system requirements make it impossible to predict what this reading will be. Mark the reading on the gauge dial or the unit for future element replacement. B. How To Replace Contaminated Element 1. Open the draincock completely to empty the bowl and flush particulates out. Failure to do so could cause a leaky valve. 2. Loosen the T-Bolt handle to release the filter body from the lid. (It is not necessary to completely remove the T-Bolt from the DAHL filter lid.) Support the filter body with your hand prior to release. 3. Remove the element with a turning motion. At this point, 3. Close the draincock and follow the priming instructions shown below. B. DAHL Units Mounted LOWER Than Fuel Storage Tank 1. Turn engine off and close shut-off valve. (Valved Manifold units may be drained and elements replaced with the engine running at idle. Close inlet and outlet valves to islolate the filter being serviced.) 2. Open the draincock completely and drain all contaminants. 3. Close the draincock and follow the priming instructions shown below. ELEMENT REPLACEMENT TROUBLESHOOTING Engine starting and power loss problems from the fuel system are usually caused by one or more of the following: A. Air Leaks 1. Fittings. Insure the O-Rings on the fittings in the DAHL filter ports are lubricated and not damaged, cracked or dirty. NOTE: When using JIC 37 fittings, be sure only mating JIC 37 fittings are used. Misalignment will occur and air leakage will result from an attempt to fasten a SAE 45 fitting to a JIC 37 fitting. Check for fitting looseness, seat dents, misalignment or unmatched threads. All fittings must be wrench tight. 2. Bubbles In The Bowl. If bubbles appear at the depressurizer cone, a leak is indicated between the fuel tank and the inlet port. NOTE: Old fuel lines (rubber hose or metal tubing) may crack when moved. Check areas around push-on fittings, pipe adapters, hose clamps, etc. If air bubbles appear at the draincock, check for particles stuck in the valve seat or a partly open draincock. Also check for defective, miscentered or unlubricated bowl gaskets. Check the bowl plug O-Ring to make sure it is not cracked or extruded out of place. The bowl plug should be hand tightened only. 3. G a s ke t s. If the lid or bowl has been removed, make sure the ga s ket grooves are clean. Inspect the ga s kets for proper seating in the grooves. Lubricate the ga s ket(s) with oil or grease. you may clean the outside of the filter body. Use only clean diesel fuel or kerosene and wipe clean. 4. Inspect the ejector spring(s) at the bottom of the body. Also check the centerpipe O-Ring and replace if hard or damaged. 5. Remove and replace the lid cover gasket. Be sure the lid groove and body lip are clean. (Grease the lid cover gasket to hold it in place before positioning.) C. Reassembly 1. Lubricate the top and bottom element gaskets. Install the element onto the centerpipe with a turning motion. 2. Fill the filter body with clean diesel fuel to within one inch of the top. 3. Double check the lid cover gasket position in the lid groove. 4. Attach the body to the lid and hand tighten the T-Bolt handle. D. Priming 1. Eliminate air use existing fuel system primer, if so equipped. If not, remove the primer plug and fill to the top with clean diesel fuel. 2. Start engine and check for leaks. NOTE: For any marine or other unit utilizing the heat deflector shield, clean the shield to remove any accumulated diesel fuel. B. Clogging And Restriction 1. Fuel Lines. Check for collapsed lines caused by sharp bends or excessive turns. Check the tank and/or filter shut-off valve(s). 2. Filter Elements. Early clogging can occur from badly contaminated fuel (micro-organism growth, rust, sludge, dirt, etc.) Always carry a spare DAHL element. Asphaltinic materials (fuel oxidation products), which are normally harmless to the injection system, can eventually plug original equipment filters remaining in the fuel system. If problems persist after the DAHL element has been replaced, also replace the other fuel filter elements. 3. Filter Inlet. Severely contaminated fuel may cause inlet plugging. In this event, close the fuel tank supply shut-off valve (if equipped) and disconnect the inlet line. Remove the bowl and clean the inlet. Should the depressurizer cone also be plugged, disassemble and clean out. 4. Bleed Back. If fuel in the DAHL filter bleeds back to the fuel tank, an air leak or reverse flow valve problem is indicated. Inspect fuel lines and fittings first as indicated above. If the reverse flow valve is clogged, use air or clean fuel to flush out. C. Malfunction Of Engine Parts Pre-existing conditions in the pumps and injectors can also cause power loss and engine starting problems. See your equipment dealer if the above troubleshooting guides do not cover your problem. WARNING: Do NOT use gasoline or any form of alcohol or anything containing it inside or outside a DAHL Model 200 or 300 Series Fuel/Water Separator.

5 MODEL 200 SPECIFICATIONS & PARTS 120 GPH (U.S.) (454 LPH) 7/8-14 w/o-ring Boss 16 3/4 In. (425.5 mm) 7 1/2 In. (190.5 mm) 7 3/4 In. (196.9 mm) 12 lbs. (5.4 kg) P 1 T-Bolt Lid Cover 3 1 Lid Cover Gasket (Incl. in 200-GK) Body 5 1 Bowl Gasket (Incl. in 200-GK) Bowl Ring Socket Head Bolt 8 1 Reverse Flow Washer (Incl. in 200-GK & 200-DEPR KIT) 9 1 Depressurizer Set (Incl. in 200-DEPR KIT) 10 1 Bowl Collar Primer Plug 12 1 Primer Plug O-Ring (Incl. in 200-GK) 13 1 Nylon Gasket (Incl. in 200-GK) 14 1 Upper T-Bolt Seal (Incl. in 200-GK) 15 1 Lower T-Bolt Seal (Incl. in 200-GK) 16 1 Centerpipe O-Ring (Incl. in 200-GK) ,-W,-30 1 Filter Element Ejector Spring Ejector Spring Clip 20 1 Reverse Flow Gasket (Incl. in 200-GK & 200-DEPR KIT) 21 1 Reverse Flow Ball (Incl. in 200-DEPR KIT) Bowl 23 1 Bowl Plug O-Ring (Incl. in 200-GK) Bowl Plug Draincock MODEL 200-MFV SPECIFICATIONS & PARTS 240 GPH (U.S.) (908 LPH) 3/4-14 NPT 16 3/4 In. (425.5 mm) 23 31/32 In. (608 mm) 10 3/4 In. (273 mm) 35 lbs. (16 kg) 1 1 Manifold Bracket Filter/Separator D 4 90 Swivel 7/8 x 1/2 In /2 In. Pipe-Thread Adapter D 4 1/2 in Butterfly Shut-Off Valve 6 4 1/2 In. Close Nipple 7 1 3/4 x 1/2 x 1/2 In. Tee 8 2 1/2 In. Elbow 9 2 Long Nipple 10 1 Drilled & Tapped Tee /8 In. NTP Plug NOTE: For Aluminum Bowl and Marine Versions of the DAHL Model 200 and 300 Series, Refer to Form

6 MODEL 300 SPECIFICATIONS & PARTS 180 GPH (U.S.) (681 LPH) 1 1/16-12 w/o-ring Boss 22 1/4 In. (565.2 mm) 7 1/2 In. (190.5 mm) 7 3/4 In. (196.9 mm) 16 lbs. (7.3 kg) P 1 T-Bolt Lid Cover 3 1 Lid Cover Gasket (Incl. in 200-GK) Body 5 1 Bowl Gasket (Incl. in 200-GK) Bowl Ring Socket Head Bolt 8 1 Reverse Flow Washer (Incl. in 200-GK & 200-DEPR KIT) 9 1 Depressurizer Set (Incl. in 200-DEPR KIT) 10 1 Bowl Collar Primer Plug 12 1 Primer Plug O-Ring (Incl. in 200-GK) 13 1 Nylon Gasket (Incl. in 200-GK) 14 1 Upper T-Bolt Seal (Incl. in 200-GK) 15 1 Lower T-Bolt Seal (Incl. in 200-GK) 16 1 Centerpipe O-Ring (Incl. in 200-GK) ,-W,-30, -MPG,-CS 1 Filter Element Ejector Spring Ejector Spring Clip Reverse Flow Gasket (Incl. in 200-GK & 200-DEPR KIT) Reverse Flow Ball (Incl. in 200-DEPR KIT) Bowl Bowl Plug O-Ring Bowl Plug Draincock MODEL 300-MF SPECIFICATIONS & PARTS 360 GPH (U.S.) (1,363 LPH) /2 NPT 22 1/4 In. (565.2 mm) 25 In. (635 mm) 12 1/4 In. (311.2 mm) 43 lbs. (19.5 kg) 1 1 Manifold Bracket Filter/Separator F 4 90 Swivel 1 1/16 x 3/4 In In. Long Nipple x 3/4 x 3/4 In. Tee 6 2 3/4 In. Elbow In. Long Nipple 8 1 Drilled & Tapped Tee 9 1 1/8 In. NTP Plug 6

7 360 GPH (U.S.) (1,363 LPH) /2 NPT 22 1/4 In. (565.2 mm) 25 In. (635 mm) 12 1/4 In. (311.2 mm) 46 lbs. (21 kg) 1 1 Manifold Bracket Filter/Separator F 4 90 Swivel 1 1/16 x 3/4 In F 4 3/4 In. Pipe-Thread Adapter F 4 3/4 In. Butterfly Shut-Off Valve 6 4 3/4 In. Close Nipple x 3/4 x 3/4 In. Tee 8 2 3/4 In. Elbow In. Long Nipple 10 1 Drilled & Tapped Tee /8 In. NTP Plug MODEL 300-MFV SPECIFICATIONS & PARTS M F V 3 Three Diesel Fuel Filter/Water Separators Manifolded with Shut-Off Valves to allow continuous operation while servicing is also available. Refer to Model 300-MFV for Parts & Specifications. EXCEPTIONS GPH (U.S.) (2,043 LPH) /4 In. (1,009.7 mm)...85 lbs. (38.6 kg) HOW THE DAHL SYSTEM WORKS The contaminated fuel enters the inlet port. 2. The T-Bolt redirects the fuel dow n ward through the c e n t e r p i p e. 3. Fuel flows through the reverse flow valve. 4. Fuel flow is spread by the depressurizer cone. 5. As fuel is discharged from the depressurizer cone, 80% of contaminant separation takes place. Most of the solid particles and water settle into the quiet zone of the bowl. 6. As the fuel rises upward, any remaining minute water droplets coalesce on cone, baffle and bowl surfaces. Droplet size and weight gradually increase, causing downward flow into the sump. 7. Fuel is filtered completely by the element, which contains HydroShield media. The clean fuel then continues upward through the outlet port and on to the pump and injection system. 7 7

8 DAHL FUEL/WATER SEPARATORS WHY DAHL? Filters are a compromise wherever located. As a one-step strainer, a filter must be porous enough to allow sufficient flow volume. This means the filters which came with the equipment are usually in the micron range. However, if a more efficient media were used, the filter would become clogged very quickly, restricting the flow and resulting in frequent, costly element changes. Not only that, many fuel filters are not designed to remove significant amounts of water, even though water is a primary cause of injector pump and nozzle damage. Water and solid contaminants displace the diesel fuels lubricative coating on precision injection components. The loss of this protection results in wear, erosion, surface pitting and eventual fuel pressure loss. THE SOLUTION DAHL s functional dual chamber, 3-stage diesel fuel filter/water separators provide efficient suction side water separation and contaminant filtration. The key is the unique DAHL patented depressurizer cone, which spreads the flow of the fuel. The fact is, the more area to flow over, the slower the flow and the greater the separation of water and dirt from the fuel. DAHL diesel fuel fi l t e r / water separators have less mechanical flow resistance because the fuel changes direction only once. COMPLETE EFFICIENCY DAHL removes virtually 100% of the water and solid contaminants. BALDWIN LIMITED WARRANTY Baldwin Filters warrants each new Baldwin or DAHL Filter Product to be free from defects in workmanship and material as follows: 1. Housings one year from date of user s purchase. 2. Electronics, Pumps and Motors 90 days from date of user s purchase. 3. Replaceable Elements, Spin-ons, Etc. d u r i n g equipment manufa c t u r e r s recommended filter service interval, if properly installed in a Baldwin recommended application. Baldwin will replace or repair at its option, free of charge, any part still in the Baldwin warranty period found by Baldwin s inspection to be defective when such product is returned to place of purchase or to Baldwin Filters with transportation charges prepaid. S p e c i fically excluded from this warranty is damage resulting from excessive force, negligence, abuse, misuse, misapplication, tampering, improper installation, fire or accident. The warranty will not apply to any filter which has been cut apart or subject to tampering. Also, damage to plastic parts of fuel/water separators caused by the use of fluids containing alcohol is not covered by this warranty. Full details of this warranty are in the Policy and Procedures Manual at the Baldwin or DAHL distributor or may be obtained from Baldwin s Service Engineering Department. Baldwin Filters Kearney NE (800) PROVEN PERFORMANCE DAHL diesel fuel/water separators have been tested and proven over millions of miles and hours under all sorts of conditions. Ask anyone who has used DAHL, or any Baldwin user, as Baldwin Filters makes DAHL products. MARINE DURABILITY Marine units 75, 100-AL, 100-M, 100-M30, 150-AL, 150-M, 200- AL, 200-M, 200-M30, 200-MMV, 200-MMV30, 300-AL, 300-M, 300-MM, 300-MM30, 300-MMV and 300-MMV30 have passed severe U.L. testing. Tests include fire endurance, vibration fatigue, impact and thermal shock. These filters have also met U.S. Coast Guard requirements for Marine Applications. CLEAN FUEL DAHL eliminates nearly all of the engine problems caused by water and solid contaminants in diesel fuel. In addition to saving you the cost of expensive repair bills and aggravation, you can expect: Longer Injection System Component Life Full Power Performance Less Element Replacement Cost SUPERIOR ENGINEERING Die Cast Aluminum Impact-resistant large transparent bowl Element service life is several times longer than conventional Easy to install, service and clean Positive air elimination Advanced spring design assures positive element seal Less mechanical resistance because of streamlined flow path B a ffle system is designed to stop emulsification and disperse trapped air Ball check valve to stop reverse flow Six series specifically designed to fit diesel engines of various capacities Authorized Dealer DAHL Products Division Form 4230 (R 4/08) 2008 Baldwin Filters, Inc. Printed in U.S.A.